Abstract: A method and system for aligning a component within a turbine casing, and a related turbine casing. In a top-on position, a location of an optical target and another, vertically spaced optical target on the joint flange are measured. After removing at least the upper casing, the optical targets' locations are measured again, and the locations of a pair of reference points on an upper surface of the horizontal joint flange are measured. A prediction offset value is calculated for the component support position in the top-on position based on the locations. The prediction offset value may include a vertical adjustment based, in part, on a translation of a triangular spatial relationship of a number of the reference points and/or a tilt angle, a horizontal adjustment, and a horizontal joint flange surface distortion adjustment. Support position is adjusted by the prediction offset value to improve alignment.

Abstract: A method and system for aligning a component within a turbine casing, and a related turbine casing. In a top-on position, a location of an optical target and another, vertically spaced optical target on the joint flange are measured. After removing at least the upper casing, the optical targets' locations are measured again, and the locations of a pair of reference points on an upper surface of the horizontal joint flange are measured. A prediction offset value is calculated for the component support position in the top-on position based on the locations. The prediction offset value may include a vertical adjustment based, in part, on a translation of a triangular spatial relationship of a number of the reference points and/or a tilt angle, a horizontal adjustment, and a horizontal joint flange surface distortion adjustment. Support position is adjusted by the prediction offset value to improve alignment.

Abstract: A turbine induction temper system. In one embodiment, an induction temper system for a turbine includes: an induction member; a control system operably connected to the induction coil; and a temperature sensor operably connected with the control system, wherein the control system is configured to control an electrical current supplied induction member in response to a temperature indicator about a component of the turbine obtained from the temperature sensor.

Abstract: A method of welding a bearing is provided. The method includes providing an apparatus including at least one welding torch and a processor, positioning a holding fixture proximate the apparatus, securing a bearing in position in the holding fixture, applying a bead of weld to facilitate repairing a damaged surface of the bearing and incrementally rotating the bearing with the apparatus.

Abstract: A turbine induction temper system. In one embodiment, an induction temper system for a turbine includes: an induction member; a control system operably connected to the induction coil; and a temperature sensor operably connected with the control system, wherein the control system is configured to control an electrical current supplied induction member in response to a temperature indicator about a component of the turbine obtained from the temperature sensor.

Abstract: The temporary fastening system for joining upper and lower shell casings of a turbine to one another for maintenance purposes includes a stud/nut tensioning system employed in lieu of the conventional studs and nuts. Once the turbine is opened up and the inner shell and rotor removed, the upper and lower shell casings are temporarily secured to one another using studs received in registering openings in the horizontal flanges of the upper and lower shell casings and retainer plates serving as a stop for the stud/nut tensioning system. The tensioning system is hydraulically operated and avoids torsional force on the temporary studs. Once measurements are made, the turbine is again reopened and reassembled using the initially removed bolts or a third set of bolts to secure the upper and lower shell casings to one another.

Abstract: A method for fabricating a rotor shaft using a welding process. The method includes positioning a first rotor shaft section adjacent a second rotor shaft section, and using a submerged arc welding process with an included weld preparation angle of between about 0° and about 30° to join the first and second rotor shaft sections together.

Abstract: Partitions have an airfoil coupled at opposite ends to inner and outer side walls. The side walls each mount radially extending male dovetails. The inner web and outer ring of a diaphragm include complementary shaped dovetail grooves. The male dovetails have reduced diameter portions while the female grooves similarly have corresponding reduced diameter groove portions. The male dovetails are inserted into the female dovetail grooves in an aft direction with stops of the reduced male and female dovetails preventing further movement aft. Seal welds are applied to prevent forward movement of the partitions relative to the web and outer ring.

Abstract: A method of welding a bearing is provided. The method includes providing an apparatus including at least one welding torch and a processor, positioning a holding fixture proximate the apparatus, securing a bearing in position in the holding fixture, applying a bead of weld to facilitate repairing a damaged surface of the bearing and incrementally rotating the bearing with the apparatus.

Abstract: A self indexing portable automated tenon peening device including: a peening machine in operable communication with a mounting arm; a circumferential slide assembly including a circumferential rail in operable communication with the mounting arm; an axial slide assembly including a axial slide rail in operable communication with the circumferential slide assembly; a base in operable communication with the axial slide assembly; and a programmable logic controller for controlling a position of the circumferential slide assembly and the axial slide assembly.

Abstract: A method of programming robotic control includes the steps of defining executable actions in a control loop, and establishing sub-programs that effect modifications of or additions to the executable actions. The sub-programs are executed according to external binary inputs. The external binary inputs are provided during execution of the control loop so that the sub-programs can be executed as part of the control loop.

Abstract: Partitions have an airfoil coupled at opposite ends to inner and outer side walls. The side walls each mount radially extending male dovetails. The inner web and outer ring of a diaphragm include complementary shaped dovetail grooves. The male dovetails have reduced diameter portions while the female grooves similarly have corresponding reduced diameter groove portions. The male dovetails are inserted into the female dovetail grooves in an aft direction with stops of the reduced male and female dovetails preventing further movement aft. Seal welds are applied to prevent forward movement of the partitions relative to the web and outer ring.

Abstract: Bucket tip tenons requiring refurbishment are removed from the bucket tips by grinding. Groups of buckets are clamped on a rotatable table in positions adjacent an induction heating coil and a robotic welding arm, respectively. While one group is preheated, the other group of buckets is in a welding location, enabling the welding head on the robotic arm to sequentially apply weld buildup material to the bucket tips. After applying weld buildup material in multiple passes and sequentially to the bucket tips, the buckets are removed, stress-relieved and the weld buildup material machined to provide refurbished tenons. Upon removal of the buckets from the table, the table is rotated to locate the preheated buckets in welding locations and additional buckets are clamped to the table for preheating.

Abstract: Bucket tip tenons requiring refurbishment are removed from the bucket tips by grinding. Groups of buckets are clamped on a rotatable table in positions adjacent an induction heating coil and a robotic welding arm, respectively. While one group is preheated, the other group of buckets is in a welding location, enabling the welding head on the robotic arm to sequentially apply weld buildup material to the bucket tips. After applying weld buildup material in multiple passes and sequentially to the bucket tips, the buckets are removed, stress-relieved and the weld buildup material machined to provide refurbished tenons. Upon removal of the buckets from the table, the table is rotated to locate the preheated buckets in welding locations and additional buckets are clamped to the table for preheating.

Abstract: A pair of stands are spaced one from the other to support opposite ends of an upper shell and diaphragm halves of a turbine at locations along the upper shell axially beyond the diaphragm halves. Carts mounted on wheels each have a hydraulically actuated lift and a platform mounting support assemblies engagable with an upper diaphragm half at the midline. By engaging a diaphragm half from below the upper shell, securing the support assemblies to the upper diaphragm half and releasing the upper diaphragm half from the upper shell by removing bolts and keys to transfer the weight of the diaphragm half to the cart, the diaphragm half may be lowered from the upper shell and moved away. The diaphragm halves may then be refurbished and the process reversed to reinstall the diaphragm halves into the upper shell. During the process, the upper shell remains in its normal orientation, similarly as in the turbine.

Abstract: An assembly for lifting and supporting a journal body with respect to a stationary body including: a support bracket for being secured to said stationary body; an elongated support member to engage and support a bottom facing surface of the journal body; first and second support studs operatively coupled at a distal end thereof to a respective longitudinal end of said elongated support member and adjustably coupled at the proximal end thereof via a respective lift assembly to said support bracket, wherein each said lift assembly comprises a hydraulic cylinder operatively coupled to said proximal end of said support stud so as to selectively determine a position of said support stud with respect to support bracket thereby to selectively adjust and determine a position of said journal body with respect to said stationary body.

Abstract: A pair of stands are spaced one from the other to support opposite ends of an upper shell and diaphragm halves of a turbine at locations along the upper shell axially beyond the diaphragm halves. Carts mounted on wheels each have a hydraulically actuated lift and a platform mounting support assemblies engagable with an upper diaphragm half at the midline. By engaging a diaphragm half from below the upper shell, securing the support assemblies to the upper diaphragm half and releasing the upper diaphragm half from the upper shell by removing bolts and keys to transfer the weight of the diaphragm half to the cart, the diaphragm half may be lowered from the upper shell and moved away. The diaphragm halves may then be refurbished and the process reversed to reinstall the diaphragm halves into the upper shell. During the process, the upper shell remains in its normal orientation, similarly as in the turbine.

Abstract: An assembly for lifting and supporting a journal body with respect to a stationary body including: a support bracket for being secured to said stationary body; an elongated support member to engage and support a bottom facing surface of the journal body; first and second support studs operatively coupled at a distal end thereof to a respective longitudinal end of said elongated support member and adjustably coupled at the proximal end thereof via a respective lift assembly to said support bracket, wherein each said lift assembly comprises a hydraulic cylinder operatively coupled to said proximal end of said support stud so as to selectively determine a position of said support stud with respect to support bracket thereby to selectively adjust and determine a position of said journal body with respect to said stationary body.

Abstract: Using sinker electrode discharge machining tools, damaged portions of partitions of the turbine which have been removed and replaced with weld material of increased thickness may be shaped and contoured to blend with the suction and pressure sides of the partitions. The diaphragm containing the partitions is located in a tank containing dielectric material. A numerically controlled EDM machine directs first and second sinker EDM tools having surfaces corresponding to designed surfaces of the trailing edge portions of the partitions applied to contour and shape the opposite surfaces of the weld material to blend with the pressure and suction sides of the partitions. A third EDM tool is used to shape the juncture at opposite ends of each partition with the arcuate surfaces of the inner and outer bands.

Abstract: An insert assembly is provided for a rotary machine wherein the rotary machine comprises a rotor and a casing. The rotor comprises a generally longitudinally-extending axis. The casing is generally coaxially aligned with the axis. The casing circumferentially surrounds and is radially spaced apart from the rotor. The insert assembly comprises a channel circumferentially disposed on the rotor and an insert circumferentially disposed in such channel such that the insert assembly is configured to thermally isolate frictional heat from the rotor to the insert.